Note: Descriptions are shown in the official language in which they were submitted.
CA 02907624 2015-09-28
An apparatus and a process for low-temperature dry distillation
of oil sand, oil sludge, oil shale and biomass
Technical field of the invention
This invention, belonging to the technical field of energy development,
relates to a system and a process for the low-temperature pyrolysis (or dry
distilling) of solid material, in particular to a system and a process of
pyrolyzing
(or dry distilling) oil sand, oil sludge (e.g. mixture of crude oil and soil,
tank bottom
oil sludge, refinery oily sludge), oil shale and biomass (xylon, straw, solid
waste
and etc.) with an externally-heated rotary furnace as a core apparatus.
Background of the invention
Percentage of oil reserves is less than 5% and percentage of natural gas is
only 0.3% of total energy reserves in China. Shortage of oil and natural gas
becomes a remarkable problem impacting economic development. Therefore,
increasing attention is paid to the development of unconventional oil and gas
energy in recent years which has become new economic development pole.
Pyrolysis techniques for oil sand, oil sludge (e.g. mixture of crude oil and
soil,
tank bottom oil sludge, refinery oily sludge), oil shale, biomass (e.g. xylon,
straw,
solid waste) and other solid material in the world mainly are the technologies
of
internally-heated vertical furnace, externally-heated vertical furnace, solid
heat
carrier, fluidized bed. Despite the advantages of simplified technology and
less
investment, internally-heated vertical heaters have a low usage rate of raw
materials, a yield of impure coal gas, severer pollution, a lower yield rate
of tar
and the like. Other techniques also have the disadvantages of redundant
technology, complicated equipment and low running rate, whereby the
techniques fail to realize the overall industrialization.
Summary of the invention
It is an object of the present invention to provide a process with an
externally-heated rotary dry distillation (or pyrolysis) furnace as a core
apparatus
for low-temperature dry distillation (or pyrolysis) of oil sand, oil sludge,
oil shale
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and biomass which overcomes the above-described disadvantages of the prior
art. The process of simplified technology and stable operation has a distinct
advantage in processing oil sand, oil sludge (e.g. mixture of crude oil and
soil,
tank bottom oil sludge, refinery oily sludge), oil shale and biomass (e.g.
xylon,
straw, solid waste) and other granulated materials.
The objects of the invention are accomplished by the following technical
scheme:
An apparatus for low-temperature dry distillation of oil sand, oil sludge, oil
shale and biomass comprises a conveying device, a stock bin connected to the
conveying device, and a metering device connected to the stock bin, the
metering
device is connected to a drying furnace and a surge bin respectively, the
metering
device is connected to a drying furnace via a 1# feeding airlock device, the
drying
furnace is connected to the surge bin via a 1# discharging airlock device; and
the
surge bin is connected to a rotary dry distillation furnace and a cooling
device in
sequence, the surge bin is connected to the rotary dry distillation furnace
via a 2#
feeding airlock device, the rotary dry distillation furnace is connected to
the
cooling device via a 2# discharging airlock device.
Further, in the apparatus:
The rotary dry distillation furnace is connected to a pyrolysis gas processing
system and a dry distillation heating system.
The rotary dry distillation furnace comprises a rotary cylinder supported by a
supporting device, and the rotary cylinder comprises a front part of the
furnace
body, a heating section of the rotary furnace body and a discharging end
connected in sequence; the front part of the furnace body is provided with a
feeding end, a gas outlet and a gearing;
the heating section of the rotary furnace body comprises three sections,
internal heating tubes are arranged along the inside of the three sections,
heat
source outlets are arranged at a front section and a middle section of the
heating
section respectively, heat source inlets are arranged at the middle section
and an
end section of the heating section respectively; and
the rotary dry distillation furnace is provided with an external
material-returning device and an internal material-returning device.
The dry distillation heating system comprises a combustion device and an air
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distribution device connected to the heat source outlets and arranged on the
combustion device; a front end of the combustion device communicates with the
heat source inlets and a tail end of the combustion device communicates with
an
end of the pyrolysis gas fuel;
a tail-end air inlet pipeline of the combustion device communicates with a
waste-heat recovery device, the waste-heat recovery device is communicated
with a fume extractor and a combustion-supporting air pipeline respectively;
and
a hot flue gas circulating device is arranged on the air inlet pipeline which
connects the air distribution device and the heat source outlets.
The cooling device comprises a cylinder supported by a supporting device,
the heat exchanging tubes arranged inside the cylinder, a shell side of a
cooler is
formed between an outer wall of the cylinder and the heat exchanging tubes; a
feeding end is arranged at the front end of the cylinder and a discharging end
is
arranged at a tail end of the cylinder, the discharging end is connected to a
cooling medium inlet via a rotary joint where a cooling medium outlet is
arranged;
a gearing is arranged on the cylinder.
Accordingly, the invention also provides a process for low-temperature dry
distillation of oil sand, oil sludge, oil shale and biomass comprising the
following
steps:
1) raw oil sand, oil sludge, oil shale or biomass is crushed and sieved to the
required particle size and delivered to a stock bin by a conveying device, and
then to the drying furnace through a 1# feeding airlock device after the
measurement by a metering device; drying furnace works by means of hot flue
gas drying or steam pipe drying, of which demanded heat is supplied by the
drying heating system which mainly comprises a combustion device, an air
distribution device, a dust-extraction device, a fume extractor and a hot flue
gas
circulating device; final temperature of dehydrated and preheated materials is
ranging from 80 C to 150 C;
2) the dehydrated and preheated raw materials is delivered to a surge bin
through a 1# discharging airlock device, and then to a rotary dry distillation
furnace through a 2# feeding airlock device;
3) the materials in the rotary dry distillation furnace is heated and dry
distilled
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CA 02907624 2015-09-28
by hot flue gas in an external heating jacket or/and internal heating tubes; a
mixing device or a material-returning device is provided for dry distillation
before
the rotary dry distillation furnace if the raw material is of high viscosity
and poor
fluidity; certain temperature and micro-positive pressure or micro-negative
pressure is maintained inside the rotary dry distillation furnace 11 and the
produced hot pyrolysis gas is sent to a tail gas treatment process to separate
and
recycle the components thereof; and
4) the solid pyrolysis products are discharged out of a furnace body through
a discharging end of the rotary dry distillation furnace, and are delivered
through
a 2# discharging airlock device and to a cooling device 9 via a feeding end 9-
5,
and then to a shell side of a cooler 9-3, after that the solid pyrolysis
products are
delivered to next process or packaged to product after cooling.
Further, in the process:
The raw materials unnecessarily dehydrated and preheated are delivered
directly from the surge bin to the rotary dry distillation furnace through the
feeding
airlock device after measurement.
In step 3, in the rotary dry distillation furnace, the reaction time of the
materials is ranging from 30 to 120 minutes, final reaction temperature is
ranging
from 300 C to 700 C, micro-positive or micro-negative pressure is maintained
and pressure value is ranging from -500 mm H20 to 500 mm H20.
In step 3, a mixing device is arranged before the rotary dry distillation
furnace
to mix sand, ceramic ball, ceramic particle or solid pyrolysis products with
raw
material which is of high viscosity and poor fluidity at the weight rate of 1-
2:1, or
solid pyrolysis products are delivered to the mixing device by a conveying
device
and mixed with the raw material which is of high viscosity and poor fluidity
at the
weight rate of 1-2:1.
In step 3, the material-returning device is provided for dry distillation if
the
raw material is of high viscosity and poor fluidity, the internal material-
returning
device or the external material-returning device is arranged to return solid
pyrolysis products to the feeding end to mix with the raw material which is of
high
viscosity and poor fluidity at the weight ratio of 1-2:1.
The technical innovations of the invention are as follows:
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1) The raw material: External heating rotary furnace has the capability of
processing solid materials with particle size of less than 30 mm which is
unable to
be processed by existing traditional techniques;
2) Highly utilization of heat: Heat utilization is high as the result of
cyclic
utilizing high-temperature flue gas, recovering waste heat of discharged flue
gas,
recovering waste heat of tailings, reducing energy consumption and saving
water
by comparison with coke wet quenching, and generating steam by steam boiler
from delivered process water;
3) Processing capacity of single set of apparatus is able to achieve
1,000,000 tons raw material per year;
4) The apparatus is flexible to operate, as technological parameters are easy
to adjust and the yields of each product can be adjusted and controlled
according
to the changes of market;
5) The apparatus is of high degree of automation, reliable running and stable
operation so as to effectively reduce the fixed number of staff members of the
apparatus;
6) High-quality products:
a. Semi-coke is waterless by using continuous dry quenching, which
improves the quality of solid products and has a distinct advantage in
environmental protection, including saving water, and reducing noxious gas and
industrial waste water;
b. Produced oil is of high quality and productive rate, of which density is
low
and light fraction content is high, percentage composition of H element is
over 9%
and is capable of serving as high-quality raw material of hydrogenation,
liquid
products yield rate reaches over 90% by Gray-king assay because of high
controllability of final heating temperature and temperature rise rate; and
c. Coal gas is of high purity and calorific value, of which effective
constituents
of CH4. H2. CO content is high and content of N2 is lower than 2%, heat value
is
over 4800 kcal/Nm3, and is capable of serving as high-quality feed gas for
producing natural gas, synthesis methanol and synthesis ammonia, and
extracting hydrogen and the like;
7) The process has wide range of application, thus different scheme and
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CA 02907624 2015-09-28
parameters are applied to different materials;
8) The process effectively solves processing problem of cohesive materials;
9) Material is mixed continuously, stably, evenly and automatically.
Brief description of the drawings
Figure us production process flow of this invention.
Figure 2 is a schematic diagram of an externally-heated rotary dry
distillation
furnace.
Figure 3 is a schematic diagram of an external material-returning pattern.
Figure 4 is a schematic diagram of an internal material-returning pattern.
Figure 5 is a schematic diagram of a cooling device for solid pyrolysis
products.
Figure 6 is a schematic diagram of a dry distillation heating system.
In the drawings:
1 ¨ Conveying Device 9-1 ¨ Cooling Medium Inlet
Jacket External Heating
2 ¨ Stock Bin 9-2 ¨ Rotary Joint 11-5 ¨ Rotary Shell
3 ¨ Metering Device 9-3¨A Shell Side Of A Cooler 11-6 ¨ Discharging
End
4¨ 1# Feeding Airlock Device 9-4 ¨ Heat Transfer Tubes 11-7 ¨ Heat Source
Inlets
5 ¨ Drying Heating system 9-5 ¨ Feeding End 11-8 ¨ Internal Heating
Tubes
6 ¨ Surge Bin 9-6 ¨ Gearing 11-9 ¨ Supporting Device
7 ¨ 2# Feeding Airlock Device 9-7 ¨ Supporting Device 11-10 ¨ Gearing
8 ¨ Dry distillation heating11-11 ¨ External
9-8 ¨ Discharging End
system Material-Returning
Device
11-12 ¨ Internal
8-1 ¨ Combustion Device 9-9 ¨ Cooling Medium Outlet
Material-Returning Device
8-2 ¨Air Distribution Device 10 ¨2# Discharging Airlock 12
¨Pyrolysis Gas
Device Processing System .
11 ¨ Rotary Dry Distillation 13 ¨ 1# Discharging
Airlock
8-3 ¨ Fume Extractor
Furnace Device
8-4 ¨ Waste-Heat Utilization
11-1 ¨ Feeding End 14 ¨ Drying Furnace
device
8-5 ¨ Hot Flue Gas Circulating
11-2 ¨ Gas Outlet
Device
9 ¨ Cooling Device 11-3 ¨ Heat Source Outlets -
Detailed description of the embodiments
Detailed description of the invention is illustrated by embodiments with
accompanying figures.
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Figure 1 is a structure diagram of the apparatus in the invention.
An apparatus for low-temperature dry distillation of oil sand, oil sludge, oil
shale and biomass is provided. The apparatus comprises a conveying device 1, a
stock bin 2 and a metering device 3 connected in sequence. The metering device
3 is connected to a drying furnace 14 and a surge bin 6 respectively; the
metering
device 3 is connected to the drying furnace 14 via a 1# feeding airlock device
4,
the drying furnace 14 is connected to the surge bin 6 via a 1# discharging
airlock
device 13; and the surge bin 6 is connected to a rotary dry distillation
furnace 11
and a cooling device 9 in sequence, the surge bin 6 is connected to the rotary
dry
distillation furnace 11 via a 2# feeding airlock device 7, the rotary dry
distillation
furnace 11 is connected to the cooling device 9 via a 2# discharging airlock
device 10. A drying heating system 5 is communicated with the drying furnace
14
which works by means of hot flue gas drying or steam pipe drying and of which
the demanded heat supplied by the drying heating system, the drying furnace 14
mainly comprises a combustion device, an air distribution device, a
dust-extraction device, a fume extractor and a hot flue gas circulating
device; and
the rotary dry distillation furnace 11 is connected to a pyrolysis gas
processing
system 12 and a dry distillation heating system 8.
Belt conveyor, chain scraper (or chain bucket) conveyor, bucket elevator or
the like is available as conveying device, and the belt conveyor is
preferably. Belt
scale, screw scale, weight loss scale or the like is available as the metering
device, and the belt scale is preferably. Drying heating system works by means
of
hot flue gas drying or steam pipe drying, of which the demanded heat is
supplied
by the drying heating system which could be the hot blast system for producing
hot flue gas by burning solid, liquid or gas fuels, or could be the boiler
system for
producing steam by burning solid, liquid or gas fuels to match different
drying
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furnace types.
As shown in Figure 2, the rotary dry distillation furnace 11 comprises a
rotary
cylinder 11-5 supported by a supporting device 11-9 , the rotary cylinder
comprises a front part of the furnace body, a heating section of the rotary
furnace
body and a discharging end 11-6 connected in sequence; a front part of the
furnace shell comprises a feeding end 11-1, an gas outlet 11-2 and a gearing
11-10; the heating section of the rotary furnace body comprises three
sections,
internal heating tubes 11-8 are arranged along the inside of the three
sections,
heat source outlets 11-3 are arranged at the front and the middle sections of
the
heating section respectively, heat source inlets 11-7 are arranged at the
middle
and the end sections of the heating section respectively; as shown in Figure 3
and Figure 4, an external material-returning device 11-11 and an internal
material-returning device 11-12 are arranged in the rotary dry distillation
furnace
11.
As shown in Figure 6, the dry distillation heating system 8 which supplies
the demanded heat to the rotary distillation furnace 11 comprises a combustion
device 8-1, and an air distribution device 8-2 which is connected to the heat
source outlets 11-3 and arranged on the combustion device 8-1, and a front end
of the combustion device 8-1 communicates with the heat source inlets 11-7 and
a tail end of the combustion device 8-1 communicates with an end of the
pyrolysis
gas fuel; and a tail-end air inlet pipeline of the combustion device 8-1
communicates with a waste-heat recovery device 8-4; the waste-heat recovery
device 8-4 is communicated with a fume extractor 8-3 and a
combustion-supporting air pipeline respectively; and a hot flue gas
circulating
device 8-5 is arranged on a air inlet pipeline where the air distribution
device 8-2
is connected to the heat source outlets 11-3.
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As shown in Figure 5, the cooling device 9, a tubular rotary cooler obliquely
installed, comprises a cylinder supported by a supporting device 9-7, heat
exchanging tubes 9-4 are arranged inside the cylinder, a shell side of a
cooler 9-3
is formed between an outer wall of the cylinder and the heat exchanging tubes
9-4; a feeding end 9-5 is arranged on a front section of the cylinder, and a
discharging end 9-8 is arranged on a tail end of the cylinder which is
connected to
a cooling medium inlet 9-1 via a rotary joint 9-2 where a cooling medium
outlet
9-9 is arranged; a gearing 9-6 is arranged on the cylinder.
The embodiment of the present invention is now described by way of the
process of low-temperature dry distillation for oil sand, oil sludge, oil
shale and
biomass, including the following steps:
1) Raw oil sand, oil sludge (e.g. mixture of crude oil and soil, tank bottom
oil
sludge, refinery oily sludge), oil shale and biomass (e.g. xylon, straw, solid
waste)
are crushed and sieved to be with required particle size and are delivered to
the
stock bin 2 by the conveying device 1, materials which is in need of drying
and
preheating according to water content and technological requirement is
measured by the measuring device 3, and then delivered to the drying furnace
14
through a 1# feeding airlock device 1;
2) The dehydrated and preheated materials is delivered to the surge bin 6
through the 1# discharging airlock device 13, and then is delivered from the
surge
bin 6 to the rotary dry distillation furnace 11 through the 2# feeding airlock
device
7; materials unnecessarily dehydrated and preheated is delivered directly from
the surge bin 6 to the rotary dry distillation furnace 11 through the 2#
feeding
airlock device 7 after measurement; drying furnace works by means of hot flue
gas or steam pipe drying, of which the demanded heat is supplied by the drying
heating system which mainly comprises a combustion device, an air distribution
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CA 02907624 2015-09-28
device, a dust-extraction device, a fume extractor and a hot flue gas
circulating
device;
3) The dehydrated and preheated materials is delivered into the rotary dry
distillation furnace 11 and moving to a furnace tail along with continuous
rotation
of the furnace, and is heated and distilled by hot flue gas in an external
heating
jacket 11-4 and/or the internal heating tubes 11-8 with a sustained reaction
time
ranging from 30 minutes to 120 minutes, and final reaction temperature of the
dehydrated and preheated materials in the rotary dry distillation furnace 11
is
ranging from 300 C to 700 C, preferably between 450 C and 650 C, and a
pressure value kept in a range of -500 mm H20 to 500 mm H20 by maintaining
the micro-positive pressure or the micro-negative pressure in the rotary dry
distillation furnace so as to get solid pyrolysis products (e.g. semi-coke,
tailings or
residue) and pyrolysis gas;
Inert substances with good fluidity (e.g. sand, ceramic ball, ceramic particle
or solid pyrolysis products) are added to the raw material which is of high
viscosity and poor fluidity so as to reduce the viscidity and improve the
fluidity of
the raw materials according to following methods:
Method 1: A mixing device is arranged before the rotary dry distillation
furnace to mix inert substances of high physical performance and stable
chemical
property (e.g. sand, ceramic ball, ceramic particle or solid pyrolysis
products) with
the raw materials at the weight ratio of 1-2:1, or the solid pyrolysis
products are
delivered to the mixing device by the conveying device to mix with the raw
materials at the weight ratio of 1-2:1,
Method 2: The solid pyrolysis products are returned to the feeding end by the
internal material-returning device 11-12 or the external material-returning
device
11-11 mixing with the raw materials at the weight ratio of 1-2:1
CA 02907624 2015-09-28
The solid pyrolysis products are returned to the feeding end 11-1 by the
internal material-returning device 11-12 or the external material-returning
device
11-11 of the furnace body to mix with the raw materials at the weight ratio of
1¨ 2:
1 so as to reduce the viscidity and improve the fluidity and the heating rate
of the
raw materials; the micro-positive pressure or the micro-negative pressure is
maintained inside the rotary reactor and the pressure value is kept in a range
of
-500 mm H20 to 500 mm H20. The produced pyrolysis gas is delivered to the tail
gas treatment process to separate and recover its constituents.
The material-returning device is the material-returning screw arranged inside
of the furnace 11 with internal material- returning method or the spiral tube
or
spiral plate set on an outer wall of the furnace body with externally
returning
material method. The material at the discharging end of the furnace body
automatically returns to the feeding end by the rotation of the furnace
without any
extra conveying device or conveying power.
The required heat of the rotary dry distillation furnace is supplied by the
dry
distillation heating system 8 or the external heating jacket or the internal
heating
tubes. The required heat of the external heating jacket and the internal
heating
tubes is provided by the dry distillation heating system. The dry distillation
heating system is a hot blast system comprising the combustion device, the air
distribution device, the fume extractor, the hot flue gas circulating device,
the
waste-heat utilization device, supporting regulation and control device and
the
like, in which solid, liquid and gas fuels are burned to generate hot flue gas
to
supply heat to the furnace.
Fuels and the preheated combustion air burn in the combustion device 8-1 to
generate fresh hot flue gas with temperature ranging from 1000 C to 1500 C
which completely mixes with the mid-temperature hot flue gas delivered by the
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hot flue gas circulating device 8-5 from heat source outlets 11-3 at the ratio
of 1 ¨
8 : 1 in the air-distribution device 8-2 to generate high-temperature hot flue
gas
with temperature ranging from 600 C to 800 C, and the high-temperature hot
flue
gas is delivered to the external heating jacket 11-4 or/and the internal
heating
tubes 11-8 through heat source inlets 11-7 so as to supply heat to the rotary
shell
11-5. The mid-temperature of hot flue gas after supplying heat to the rotary
shell
11-5 is ranging from 400 C to 600 C, which is delivered from heat source
outlets
11-3 to the hot flue gas circulating device 8-5 and then separately delivered
to the
air distribution device 8-2 and the waste-heat utilization device 8-4. The
mid-temperature hot flue gas in the waste-heat utilization device 8-4
transfers
heat to the combustion air and becomes low-temperature hot flue gas with a
temperature of 180 C or less, and then enters the fume extractor 8-3 after
desulfurization and denitrification (desulfurization is not required when the
content of sulfur dioxide in flue gas meet the emission standard.) or directly
enters the fume extractor to be discharged.
There is provided a dry distillation furnace, an externally-heated rotary
furnace installed horizontally and obliquely, of which the shell is supported
by
supporting device 11-9 and the required power for rotation is from external
motivation transferred by gearing 11-10. The produced gas by distillation is
discharged from gas outlet 11-2 and is delivered to the pyrolysis gas
processing
system 12; a plurality of internal heating tubes 11-8 are arranged inside of
the
rotary shell to supply heat to the material in order to increase heat transfer
area
and enhance heat transfer efficiency, or internal heating tubes are able to be
provided alone without providing external heating jacket additionally. In
addition,
external material-returning device 11-11 arranged on the outer wall of the
shell or
the internal material-returning device 11-12 arranged inside the rotary shell
is
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CA 02907624 2015-09-28
applied to return the pyrolysis products from the discharging end 11-6 to the
feeding end 11-1.
4) The solid pyrolysis products are discharged out of the furnace body
through the discharging end 11-6 of the rotary dry distillation furnace, and
then is
delivered to the cooling device 9 through a 2# discharging airlock device 10,
where the products are cooled to 50 C to 120 C, and is finally delivered to
the
next process or packaged.
The cooling device 9 is a tubular rotary cooler obliquely installed. The solid
pyrolysis products discharged out of the rotary dry distillation furnace 11
are
delivered into the cooling device 9 through the feeding end 9-5 and then to a
shell
side of a cooler 9-3, and moving towards the discharging end 9-8 along with
the
rotation of the shell to be discharged out of the cooler to the next process.
The
cooling medium is delivered from the cooling medium inlet 9-1 to the heat
transfer
tubes 9-4 through the rotary joint 9-2 for transferring heat with the solid
pyrolysis
products from the shell side of the cooler 9-3, and finally is discharged
through
the cooling medium outlet 9-9; the rotary cylinder is supported by the
supporting
device 9-7, of which the required power for rotation is from external
motivation
transferred by the gearing 9-6. The cooling medium can be circulating cooling
water or desalted water, and the cooling medium is adopted for the following
applications:
Method 1. After cooling the material, the medium is delivered to the drying
furnace to preheat the raw materials, and then is cooled for circulating use;
Method 2. After exchanging heat, the medium is delivered to the drying
furnace for preheating the raw materials, and then to the boiler for
generating
steam;
Method 3: The medium is directly delivered to the boiler to produce steam.
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The cooling methods include direct or indirect cooling or coke quenching by
using water, direct or indirect cooling (or coke quenching) by using cold
pyrolysis
gas, cold inert gas or steam, among which using water to transfer heat
indirectly
by a tubular rotary cooling furnace is preferable. The cooling of the solid
pyrolysis
products by the tubular rotary cooler has the advantages of high efficiency of
heat
transfer, favorable operation environment, and easy recovery and utilization
of
the heat delivered by the cooling medium.
There is provided a technology that processes raw materials, which includes
oil sand, oil sludge (e.g. mixture of crude oil and soil, tank bottom oil
sludge,
refinery oily sludge), oil shale, biomass (e.g. xylon, straw, solid waste) and
their
mixture, of particle size ranging from 0 mm to 50 mm, within which a
preferable
selection is 0 mm to 25 mm.
Detailed description of the invention is illustrated by following embodiments.
Embodiment 1
1 )Raw oil sand is crushed and sieved to be with particle size of 6 mm or
less,
the bulk density of the raw oil sand is 1200 kg/ m3, and its proximate
analysis
result is shown below:
No. Test Item Result
1 Moisture (Mad) 0.74%
2 Ash Content (Aad) 78.07%
3 Volatile Matter (Vad) 16.33%
4 Fixed Carbon (FCad) 5.60 %
2) Raw oil sand is delivered to a raw material storage bin and is measured by
a belt scale and through a star unloader, the raw oil sand is delivered to the
rotary
dry distillation furnace through the surge bin at the speed of 1.2 t/h.
3) The materials delivered to the rotary dry distillation furnace is mixed
with
500 C tailings of which the weight is 3 times as the raw materials delivered
by an
internal material returning screw at the front end of the dry distillation
furnace.
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The mixture flows continuously towards the furnace tail and is heated and dry
distilled for 60 minutes by circulating hot flue gas in the external heating
jacket at
the pressure value of 300 mm H20, finally heated to the temperature of 500 C.
Sand tailings, oil from oil sand and pyrolysis gas are produced after
distillation.
Partial of the sand tailings is discharged from the tail of the rotary dry
distillation
furnace through the star unloader to a rotary cooling furnace for cooling, and
the
rest is returned to the furnace head by the internal material-returning screw
to mix
with raw oil sands at the weight ratio of 2:1 so as to improve the fluidity of
the raw
materials.
4) The tailings from the discharging end of the rotary dry distillation
furnace is
delivered to the shell side of the cooler of the tailings and moves towards
the
discharging end along with the rotation of the cooler shell. Cooling medium,
which
is circulating cooling water of 31 C, is delivered from the cooling water
inlet to the
heat transfer tubes through the rotating joint for transferring heat, and is
heated
up to 37 C after transferring heat with the tailings in the shell side of the
cooler,
and then is discharged through a cooling water outlet and recycled after
cooled.
The tailings in the cooling furnace is cooled to be less than 120 C and
delivered
to the storage yard of the tailings by the belt conveyor for storage.
The rotary dry distillation furnace is supplied with heat in the following
ways:
producer gas from coal-gas producing system burns completely with proper
quantity of air which is supplied by air blower and exchanged heat with hot
flue
gas in the air heat exchanger to produce hot flue gas. The hot flue gas mixes
with
partial circulated hot flue gas supplied by the high-temperature circulation
blower
at the tail of the burner, and then enters hot blast pipe, after the
adjustment of flap
valve at the end of hot blast pipe, hot flue gas enters external heating
jacket of the
rotary dry distillation furnace to heat the furnace body. The majority of the
hot flue
CA 02907624 2015-09-28
gas circulates in the heating system and the rest is discharged after
preheating
air.
Embodiment 2
1) Raw oil sand is crushed and sieved to be with particle size of 6 mm or
less,
its proximate analysis result is shown below:
16
Fischer Assay
Ash Fusion Point
Proximate Analysis%
C
Oil Mineral High
Calorific Specific
Content ____________________ Carbon
____________________________________________________________________________
Value Weight
Dioxide
Soften
Moisture Volatile Ash
Deforma-tion
(Mad) (Vd) (Ad) ,r12u A oi_
Tempe Shale Shale
Gas+
kcal/kg
-ing Melting t/m3
% 1/4" µ-' i
Moi-sture Tempe Tempe
Oil Semi-coke
Loss -rature
-rature -rature T3
% %
T1 %
T2
7.83 3.50 17.45 75.41 3.32 6.36 2.96 87.94 2.75
1288 1332 1370 1405 1.9-2.2
P
Ash Component r.,
Heat Intensity, >25mm,To
%
c,
-,
r.,
Average Specific
.
Heat
r.,c,
Heat Intensity
Heat Intensity of Ash kcal/kg. C
Na20
of Semi coke
u,
'
Intensity of Raw Shale SiO2Si02 A1203
Fe2O3Fe203 CaOCa0 MgOMg0 c,
K20,
Normal Temperature 900 C
etc
N)
550 C
0
82.5 79.7 41.7 0.24
60.8-62.9 21.6-30.5 5.3-11.6 0.66-1.6 1.1-
2.0 0.65
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CA 02907624 2015-09-28
2) Raw oil shale is delivered to a raw material storage bin by a belt and is
measured by a belt scale, and then to a steam-pipe drying furnace through a
star
unloader at the speed of 4.2 t/h for preheating the raw material to 100 C with
less
than 0.5% moisture content, continuously moves towards the furnace tail as the
shell rotates, and is finally discharged from the furnace body through a
discharge
bin of the furnace tail. The dust within the dry tail gas is separated and
collected
by a first-level cyclone separator and a first-level bag-type dust collector.
3) The dehydrated and preheated oil shale is delivered from a star unloader
to the rotary dry distillation furnace through a slide pipe, continuously
flows
towards a furnace tail as the furnace body rotates, and is heated and dry
distilled
for 90 minutes by circulating hot flue gas in the external heating jacket, at
a
pressure value of 200 mm H20, finally to 550 C for thermal cracking so as to
produce shale semi-coke and high-temperature gas mixture of shale oil and
pyrolysis gas, and then the gas mixture is delivered to an oil-vapor recovery
system for separating and recycling oil shale and pyrolysis gas.
The analysis result of shale semi-coke is shown below:
Calorific
Mad, % Aad, % Vad, % FCad,% Value,
Kcal/kg
0.03 81.4 9.07 9.5 538
The analysis result of shale oil is shown below:
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CA 02907624 2015-09-28
Item Result
Specific Weight g/cm3 0.90..
Tar Acid %(volume) 3.7
Tar Base %(volume) 2.5
Kinematic Viscosity cp (centipoises) 10.3
Freezing Point C 33
Paraffin Content 20.2
Asphaltene 0.85
Colloid Content 0/0 42
(Sulfuric Acid Method)
Initial Boiling Point C 216
10% Distillation Temperature C 264
20% Distillation Temperature C 293
Distillation Range
30% Distillation Temperature C 318
40% Distillation Temperature C 343
50% Distillation Temperature C 362
cyo 85.39
12.09
% 0.54
Element Composition N % 1.27
0 0.71
C/H 7.06
Characteristic Factor 11.52
The analysis result of pyrolysis gas is shown below:
Main Components of Pyrolysis Gas
w%
CO2 CnHri, CO H2 CnH2n+2
61.37 7.80 6.84 4.86 19.12
4) The shale semi-coke from a discharging end of a rotary dry distillation
furnace is delivered to the shell side of the cooler and moves towards the
discharging end as the cylinder of the cooler rotates. Cooling medium, which
is
desalted water of 25 C, is delivered from a cooling water inlet to heat
transfer
tubes through a rotating joint for transferring heat with the semi-coke in the
shell
side of the cooler and is heated up to be 70 C, and is discharged through a
cooling water outlet to a gas-fired boiler so as to supply steam to the steam
pipe
drying furnace. The shale semi-coke is cooled to be less than 80 C in the
cooling
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CA 02907624 2015-09-28
furnace and then delivered to the semi-coke storage yard by a belt conveyor.
The rotary dry distillation furnace is supplied with heat in the following
ways:
heavy oil completely burns with proper quantity of preheated air in proportion
to
produce hot flue gas. The hot flue gas mixes with partial circulated hot flue
gas
supplied by the high-temperature circulation blower at the tail of the burner,
and
then enters hot blast pipe, after the adjustment of flap valve at the end of
hot blast
pipe, hot flue gas enters an external heating jacket of the rotary dry
distillation
furnace to supply heat for the furnace body. The majority of the hot flue gas
circulates in the heating system and the rest is discharged after preheating
air.
Pyrolysis gas is delivered to a gas fired boiler to generate steam for steam
pipe
drying furnace.
Embodiment 3
1) Sieved and tattered raw sawdust is briquetted to be with particle size of 6
mm or less by a impact briquetting machine, whose main performance indexes
are shown below:
Forming density: 1.4 t/m3
Moisture content: 14%
Calorific value: 14 MJ/kg
2) Sawdust briquettes are delivered to a raw material storage bin by a belt
and are measured by a belt scale, and then are delivered to a rotary drying
furnace through a star unloader at the speed of 0.8 t/h. The raw material is
rotating with the rotation of the drying furnace and lifted up by lifting
plate installed
inside of the drying furnace, and then dropping down evenly, during its
dropping
the material fully contacts with hot flue gas from a combustion furnace so as
to
preheat the material to 80 C to remove the moisture within and the gas
absorbed
in the pores of sawdust briquettes, and then the material moves towards to a
tail
CA 02907624 2015-09-28
of the furnace with rotation of a cylinder and finally discharged out of a
furnace
through a discharging bin of the furnace tail. Small amount of dust within a
dry tail
gas is separated and collected by a first-level gravity dust separator and a
first-level bag-type dust collector.
3) The dehydrated and preheated sawdust briquettes are delivered from a
star unloader to the rotary dry distillation furnace through an slide pipe ,
continuously flow towards a furnace tail as a furnace body rotates, and are
heated and dry distilled for 60 minutes by circulating hot flue gas in an
external
heating jacket and internal heating tubes, at a pressure value of 500 mm H20,
finally to 550 C for thermal cracking so as to generate charcoal, and
high-temperature gas mixture of wood tar, wood vinegar and pyrolysis gas, the
gas mixture is delivered to an oil-vapor recovery system for separating and
recycling wood tar, wood vinegar and pyrolysis gas.
Calorific value of charcoal: 3600 kcal/kg
Moisture content of wood tar: 10%
Acetic acid content of wood vinegar: 69%
Components of pyrolysis gas:
Main Components of Pyrolysis Gas,
Calorific
Density
vo I% Value
kg/m3
H2 CO2 C3H6 C3H6 C2H4 C2H6 02 N2 CH4 CO MJ/m3
28.1 23.6 0.7 0.4 0.5 1.3 0.7 2.0 26.0 18.6
1.0 17.4
4) The
charcoal from a discharging end of the rotary dry distillation furnace
is delivered to the shell side of the cooler of the charcoal, moves towards
the
discharging end as the cylinder of the cooler rotates. Cooling medium, which
is
circulating cooling water of 31 C , is delivered from a cooling water inlet to
heat
transfer tubes through a rotating joint for transferring heat with the
tailings in the
shell side of the cooler to be heated up to 37 C, is discharged through a
cooling
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water outlet and recycled after being cooled. The charcoal in the cooling
furnace
is cooled to be less than 60 C and is delivered to the charcoal packaging
process
by a belt conveyor.
The rotary dry distillation furnace is supplied with heat in the following
ways:
heavy oil completely burns with proper quantity of air which is supplied by
air
blower and exchanged heat with hot flue gas in the air heat exchanger to
produce
hot flue gas. The hot flue gas mixes with partial circulated hot flue gas
supplied by
the high-temperature circulation blower at the tail of the burner, and then
enters
hot blast pipe, after the adjustment of flap valve at the end of hot blast
pipe, hot
flue gas enters external a heating jacket of the rotary dry distillation
furnace to
supply heat for the furnace body. 75% of the hot flue gas circulates in the
heating
system and the rest is discharged after preheating air. Hot flue gas produced
by
the combustion of pyrolysis gas supplies heat for the drying furnace.
Embodiment 4
1 )Raw oil sand is crushed and sieved to be with particle size of 6 mm or
less,
its proximate analysis result is consistent with that of the embodiment 1.
2) Raw oil sand is delivered to a raw material storage bin by a belt and is
measured by a belt scale, and then to a rotary drying furnace through a star
unloader at a the speed of 4.2 t/h. The raw material is rotating with the
rotation of
the furnace and lifted up by lifting plate installed inside of the drying
furnace, and
then dropping down evenly, during its dropping the material fully contacts
with hot
flue gas from combustion furnace so as to preheat the material to 100 C to
remove the moisture within and gas absorbed in the pores of oil sand, and then
the material moves towards to a tail of the furnace with rotation of a
cylinder and
finally discharged out of the furnace through a discharging bin of the furnace
tail.
Dust within the dry tail gas is separated and collected by a first-level
gravity dust
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separator, a first-level bag-type dust collector and a first-level
electrostatic dust
collector.
3) The dehydrated and preheated oil shale is delivered from a star unloader
to the rotary dry distillation furnace through a slide pipe, mixes with dry
river sand
-- (using river sand at the initial stage, using tailings instead after
tailings is
produced in the dry distillation furnace,) to improve the fluidity,
continuously flows
towards a furnace tail, and is heated and dry distilled for 60 minutes by
circulating
hot flue gas in an external heating jacket, at a pressure value of -500 mm
H20,
finally to 500 C for thermal cracking so as to generate tailings, oil from oil
sand
-- and pyrolysis gas.
4) The tailings from a discharging end of the rotary dry distillation furnace
is
delivered to a water-sealing discharge bin where the tailings directly
contacts
water and is cooled to be less than 50 C with moisture content within 20%,
taken
out from water by a scraper conveyer, and delivered to a storage yard of
tailings
-- by a belt conveyer.
Pyrolysis gas is delivered to a drying heating system to generate hot flue gas
for the drying furnace.
Embodiment 5
1) Raw oil sand is crushed and sieved to be with particle size of 6 mm or less
-- and the bulk density of the raw oil sand is 1200 kg/ m3, and its proximate
analysis
result is shown below:
No. Test Item Result
1 Moisture Mad 0.74%
2 Ash Aad 78.07%
3 Volatile Vad 16.33%
4 Fixed Carbon FCad 5.60%
2) Raw oil sand is delivered to a raw material storage bin by a belt and is
measured by a belt scale, and to an externally-heated drying furnace through a
23
CA 02907624 2015-09-28
star discharge bin at the speed of 4.2 t/h. The raw materials is preheated to
50 C
by the medium of demineralized water of 70 C from a cooling furnace,
continuously moves towards a furnace tail with the rotation of a cylinder, and
then
is discharged from a preheating furnace body through a discharge bin of the
furnace tail.
3) The preheated oil sand is delivered from a star unloader to the rotary dry
distillation furnace through a slide pipe , continuously flows towards the
furnace
tail as a furnace body rotates, and is heated and dry distilled for 90 minutes
by
circulating hot flue gas in an external heating jacket, at a pressure value of
300
mm H20, finally to 500 C for thermal cracking so as to generate tailings, oil
from
oil sand and pyrolysis gas which is delivered to an oil-vapor recovery system
for
separating and recycling oil from oil sand and pyrolysis gas.
4) The tailings from a discharging end of the rotary dry distillation furnace
is
delivered to the shell side of the cooler the tailings and moves towards the
discharging end with the rotation of the cooler shell. Cooling medium, which
is
demineralized water of 25 C, is delivered from the cooling water inlet to heat
transfer tubes through a rotating joint, the temperature of the cooling medium
is
heated up to 70 C after transferring heat with the tailings in the shell side
of the
cooler, and then is discharged through a cooling water outlet to an external
preheating furnace for preheating raw oil sand, and then the temperature
reduces
to be less than 100 C and delivered to the storage yard of the tailings by a
belt
conveyor for storage.
The rotary dry distillation furnace is supplied with heat in the following
ways:
producer gas from coal-gas producing system burns completely with proper
quantity of air which is supplied by air blower and exchanged heat with hot
flue
gas in the air heat exchanger to produce hot flue gas. The hot flue gas mixes
with
24
CA 02907624 2015-09-28
partial circulated hot flue gas supplied by the high-temperature circulation
blower
at the tail of the burner, and then enters hot blast pipe, after the
adjustment of flap
valve at the end of hot blast pipe, hot flue gas enters an external heating
jacket of
the rotary dry distillation furnace to supply heat for the furnace body. The
majority
of the hot flue gas circulates in the heating system and the rest is
discharged after
preheating air.
Embodiment 6
1) Oily sludge, mixture of crude oil and soil of viscous solid in paste shape,
is
adopted, whose analysis result is shown below:
No. Test Item Unit Result
1 Moisture (Mad) 19.96
2 Ash (Ad) 2.15
3 Volatile (Vdaf) cyo 96.17
4 Fixed Carbon (FCad) 3.00
5 Char Residue Characteristics
(CRC) 1-8 2
6 Total Sulfur (dry basis) (St,d) % 0.45
Carbon (dry basis) (Cd) 74.20
Hydrogen (dry basis) (Hd) 14.12
7 Element Analysis
Nitrogen (dry basis) (Nd) 0.47
Oxygen (dry basis) (0d) 8.61
Yield of Total Water(Water,ad) 16.50
Gray-King Yield of Tar (Tar,ad) % 82.30
8 Low-temperature
Yield of Semi-coke (CRad) 0.70
Dry Distillation
Coal Gas+Loss % 0.50
The raw oil sludge completely mixes with tailings (using sand, ceramic ball,
ceramic particle or solid pyrolysis products with particle size of 8 mm or
less at
the stage of furnace start-up without tailings) in a mixing device at the
weight ratio
of 1:2 so as to form loose mixed materials.
2) Mixed materials is delivered to a raw material storage bin by a belt and is
measured by a belt scale, and then to an externally-heated drying furnace
through a star unloader at the speed of 2.4 tJh for dehydrating the water
content
to be 5% or less and heating up to 80 C by using steam as the medium, and then
continuously move towards a furnace tail as the cylinder rotates, and is
finally
CA 02907624 2015-09-28
discharged from the preheating furnace body through the discharge bin at the
furnace tail.
3) The preheated mixed materials is delivered from a star unloader to the
rotary dry distillation furnace through a slide pipe , continuously flows
towards a
furnace tail as a furnace body rotates, and is heated and dry distilled for 60
minutes by circulating hot flue gas in an external heating jacket, at a
pressure
value of 200 mm H20, finally heated to 550 C for thermal cracking so as to
produce tailings, pyrolysis oil and pyrolysis gas which is delivered to an oil-
vapor
recovery system for separating and recycling pyrolysis oil and pyrolysis gas.
4) The tailings from a discharging end of the rotary dry distillation furnace
is
delivered to the shell side of the cooler of the tailings, moves towards the
discharging end as the cylinder of the cooler rotates. Cooling medium which is
demineralized water of 25 C is delivered from a cooling water inlet to heat
transfer tubes through a rotating joint for transferring heat with the
tailings in the
shell side of the cooler to be heated up to 37 C, is discharged via a cooling
water
outlet and delivered to an air cooler for cooling, and then recycles for
using.
Partial of the tailings which is cooled to be less than 80 C is delivered to a
mixing
device by a belt conveyer, and the rest is to the storage yard.
The rotary dry distillation furnace is heated by same method as that of the
embodiment 5.
It shall be noted that the foregoing description represents the preferable
embodiments of the present invention, and is intended to illustrate and not
limit
the scope of the invention. While the invention has been described hereinabove
in detail in conjunction with the embodiment, those skilled in the art can
modify
the technical solutions or make equal substitutions in technical features of
the
embodiments.
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All modifications, substitutions or improvements, made by those ordinarily
skilled in the art without departing from the spirit and scope of the present
invention, are intended to be included within the scope of the invention.
27
